Air Conditioning Installation and

Operating Instructions

Blue Cool Premium

Ident.-Nr.: 0903071A Webasto AG, Global Comfort Solutions © 2007 All Rights Reserved

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 Webasto - Marine Air Conditioning
F CHILLED WATER AIR-CONDITIONING SYSTEMS
OPERATING AND INSTALLATION MANUAL
U
N
IES 2ND AIR-HANDLER - VERTICAL
SLIM-LINE MODEL

SER TRANSITION BOX +

C
4
SUPPLY AIR-GRILLE

FLEXIBLE AIR-DUCT
0
T
- 20
S
DIGITAL CABIN

C
CONTROL PANEL

I
AIR-HANDLER -
I
N
COMPACT SERIES

O
O
CTR
E
N
EL
EW
I
N
N RETURN AIR GRILLE Tee JUNCTION
TO 2ND AIR-
HANDLER

G
TUBULAR INSULATION
AROUND CHILLED
WATER CIRCUIT
PIPING

OVER-BOARD DIS-
CHARGE

P
CHILLER UNIT
DIGITAL CONTROL
R PANEL

I
CIRCULATION PUMP

N CHILLER UNIT
SEA-WATER PUMP ELECTRICAL CONTROL BOX

C CHILLER UNIT

I COOL CYCLE LED

ROOM TEMPERATURE OR
ONTROL PANEL SET-POINT TEMPERATURE
D I G IT A L C OR SECONDARY FUNC-
P AUTO CYCLE SWITCHING LED TION READ-OUT
COMPRESSOR RUN LED

L HEAT CYCLE LED

SET-POINT MODIFICATION
KEYS
E MAIN ON/OFF SWITCH

S FUNCTION KEY / SECONDARY COMMANDS BLOWER KEY

Webasto AG - Special Products & Markets
Kraillinger Strasse 5, 82131 STOCKDORF, Germany
Tel. : +49(0) 89 8 57 94 543 Fax : +49(0) 89 8 57 94 753 Website : www.webasto.de
EDITION DATED 21ST AUGUST 2006 CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 1

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 2

CHILLED WATER AIR-CONDITIONING SYSTEMS

OPERATING AND INSTALLATION MANUAL

CONTENTS
Page
1) General information ................................................................................................... 3

2) Digital Display <CHILLER CONTROL> .................................................................. 3

2.1 - Drawing Digital Display - Operation Guide........................................................ 3

3) Central Blower Control ............................................................................................... 4

4) Visual Error Codes Digital Display ............................................................................ 4

5) Cabin Blower Control ................................................................................................. 6

5.1 - Wiring diagram - <CAB> 230V AC Cabin Control .......................................... 7

6) Programmable Functions Chiller Condensing Units .................................................. 9

6.1 - Digital Display - Programming access ............................................................... 9

7) Pratical Installation of Components - Guidelines ....................................................... 11

7.1 - Installation Drawing - Sea Water Pump system ................................................. 11

8) Chilled Water Circuit Installation ................................................................................ 12

8.1 - Integration of Added Heat-Exchangers in Chilled Water Circuit ....................... 12
Golden Rules - Chilled Water Piping Installation ....................................................... 13
Filling and Purging of a Chilled Water Circuit ........................................................... 14
Examples of Chilled Water Circuit Piping Schematics .............................................. 15
8.6 - Example Chilled Water Circuit Piping - Small 20000 BTU Chiller .................. 15
8.7- Example Chilled Water Piping - WBCP24/D Stern Location - 4 Air-Handlers . 15
8.8 - Example - Catamaran - WBCP36/D - Central Location - 6 Air-Handlers ......... 16
8.9 - Example - Motoryacht - WBCP72/D Twin - Aft location - 10 Air-handlers ..... 17

8F - Air Ducts - Ventilation .............................................................................................. 18

9) Routine Checks/Trouble Shooting............................................................................... 19

11) Wiring diagrams ......................................................................................................... 20

11.1 - Wiring diagram single compressor WBCP12/16/20/24/30 - 1 phase................ 21
11.2 - Wiring diagram single/twin compressor - 1/3 phase ....................................... 22
11.3 - Wiring diagram compressor 3/4 - single and 3 phase ..................................... 23
11.4 - Power Supply Schematics - TWIN/CI Chillers - single phase 230V .............. 24
11.5 - Power Supply Schematics - TWIN/TRI (3) compr. Chillers - 1 phase 230V . 24
11.6 - Power Supply Schematics - TWIN/TRI (3) compr. Chillers - 3 phase 400V . 25
11.7 - Wiring Diagram automatic staging secondary AC loads .................................. 26
11.8 - Wiring Diagram - Running Capacitors - ECOFIT Blowers ............................ 26
11.9 - Wiring Diagram - Connection 3-Way valve (Lizhan/Zhongli) on TECC card 26
Webasto AG - Special Products & Markets
Kraillinger Strasse 5, 82131 STOCKDORF, Germany
Tel. : +49(0) 89 8 57 94 543 Fax : +49(0) 89 8 57 94 753 Website : www.webasto.de

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 2

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 3

1 - GENERAL INFORMATION - CHILLER AIR CONDITIONING SYSTEMS

As from May 2004 all WEBASTO air condi-
tioning units are controlled by a Digital
Display <CHILLER CONTROL> 2004
SERIES which gives access to all functions
necessary for the normal operation of the unit
and attached accessories (blowers, pumps,
etc).
2) 3 small LED’s to the left indicating the
operating cycle presently active :
- Cool cycle only operation.
- Automatic cycle switching governed by
the end-users entered set-point temperature.
- Heat cycle only operation.
Programming Commands - Level 3 :
A number of programming commands that
do not need to be accessed for day to day
operation are hidden and require a special
procedure to enable access and modification.

All WEBASTO air conditioning units are
sea-water cooled by means of an AC sea-
water pump.
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 components as well as it
normal functioning.
The digital display will show the present
room temperature of the cabin in which the
digital display is situated or where the main
temperature sensor is located (in case the
optional secondary temperature sensor is
used).
The WEBASTO <CHILLER CONTROL>
digital display allows access to information
and controls at three distinct levels :
3) 2 set-point keys give immediate access
to the thermostatic set-points for blower-
control (“Sun” and “Snow” key).
These keys are also used to alter program-
ming values - see here-after chapter 6.
Press and hold one of the set-point selector
keys and wait until the new desired set-point
temperature is obtained. Release the set-
point key.
The display will memorize the value and
return to normal room temperature read-out
after approx. 5 seconds.
Secondary commands and info -
Level 2 :
The F/Blower key gives immediate access to
a number of secondary commands which
need to be accessed frequently for day to day
operation.
An access code can be enforced to avoid
accidental modification of programming val-
ues.
See Chapter 6 - Page 9.
Start-up delay :
After pushing the On/Off key the LED’s will
display <On> while initializing the system.
Push again to stop operation - the display
will briefly show <Off> before extinction.
The adequate LED to the left (heat, cool , etc)
will come on after approx. 15 seconds and
compressor operation will start after approx.
50 seconds.
The chilled water circulation pump will
come on immediately after system initializa-
tion.

Immediate Access - Level 1 : First access is to the blower speed control, New features - 2004 Series :
then chilled water temperature read-out, etc.
1) Room temperature read-out in the main 4 As from June 2004 all WEBASTO air condi-
LED display window tioning units are controlled by a new Digital
See hereafter drawing 2.1 for complete list.
Display <AIR CONTROL> 2004 SERIES
2.1 - <CHILLER CONTROL> DIGITAL DISPLAY - OPERATING GUIDELINES
4 BASIC COMMANDS :
1 - Press to turn on - press again to turn off.
2 - Press to read set-point temperature - hold to raise
set-point temperature.
3 - Press to read set-point temperature - hold to lower
5 set-point temperature.
4 - Led indicating system working in cool cycle
5 - Led indicating automatic reversed cycle mode is operative
6 6 - Led indicating system working in heat cycle
7 - Function/Blower Key - immediate access to : *Default Values
- chilled water temperature read-out .................... H13.2
- manual choice of operating cycle (cool only, ..... *F 3
heat only, etc)
- AC voltage read-out ........................................... U230
1 - manual compressor selection On/Off 1 to 4. 1C01 etc
7 8 2 - start-up priority compressors 1 to 4.................... P123 etc
3
- time delay between compressor start-up............. *L 9
- individual thermostatic advance compressors .... 1L0.0 etc
- automatic dehumidification cycle during absence *d 0
- display time of secondary functions accessible by *t 1
9 - Push Both Keys Simultaneously F/Blower key
after Display Extinction. 8 - Dedicated Blower speed key ................................ *b A

NB - System stops while displaying 3 lettres <AAA> : safety 9 - Access to hidden programming functions - see
cut-out because of persistent low voltage. To restart make sure Chapter 6 - page 9
voltage level is raised above 195V AC

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 3

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 4
which gives access to all functions necessary
for the normal operation of the unit and
attached accessories (blowers, pumps, etc).
2004 Series Electronic Controls are easily
recognized by their special remobale bezels.
The new 2004 displays are backwards com-
patibel with the older TCC electronic con-
troller cards. In that case however the dedi-
cated Blower key is not operational.
Continued features - 2000 Series :
A) Automatic blank/sleep mode - pro-
grammable time delay. Factory default : 15
minutes. While in blank/sleep mode the cycle
LED flashes discretely every 20 seconds. To
go back to normal operation push any key.
B) Calibrate all blower speed settings
in real time mode.
It is now possible to calibrate all speed set-
tings (1 to 5) before actually putting the sys-
tem into service.
To do so enter programming mode with set-
point at 15° C.; proceed to line <6> = speed
5 (max). (see chapter 6 - page 9)
The blower will start to function as soon as
you access code <6>.
Alter the value to the right of code <6> and
the blower speed will immediately change in
real time. When satisfied go to following line
<7> = speed 4 and do the same.
Proceed until lowest speed N° 1 and go back
again to speed N° 5 if not satisfied.
When all speeds are programmed according
to need, validate by pushing on/off key
(<memo> will be displayed briefly).
Attention : Never program speeds
so low that the blower is in danger
of stopping or will not re-start at
that setting.
This will inevitably entail motor-
windings burn-out and will not be
covered by the WEBASTO warran-
ty.
C) Infra-Red Remote Control :
Infra-red remote control can be purchased as
an option. This remote control is based on the
standard protocols also used by TV and other
appliances. Although the WEBASTO con-
trols have been chosen so as to avoid inter-
ference with most TV models, the end-user
should be aware that in certain cases interfer-
ence may occur with TV sets or other appli-
EDITION DATED 21ST AUGUST 2006
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ances.
Generaly, it is therefore advisable to avoid
locating a WEBASTO <AIR CONTROL>
display next to other appliances using infra-
red control units.
D) ACCESS CODE :
The end-user can deny access to all program
settings by introducing an access code (see
page 10 - code <b>). Blower speed and set-
points always remain accessible.
Once an access code is activated, the digital
display will show <Code> if the end-user
tries to access other functions then blower
speed or set-point temperature. To gain full
access push the sun key to reach the code
value as programmed and push the F key
again to gain access to full program settings.
3 - CENTRAL BLOWER CON-
TROL
The central <CHILLER CONTROL> digital
display which controls general operation of
the condensing unit(s) can also directly con-
trol the blower(s) of the saloon/cabin where
the main temperature sensor is located.
This direct blower control is optional and not
all installations use this facility to control a
part of the ship’s blowers.
Blowers in the wheel-house for instance,
where the <CHILLER CONTROL> display
is located, can be directly controlled by the
TECC card. The <FAN> outlet of the TECC
controller card offers manual speed settings
and thermostatic control in the same manner
as the individual cabin controls.
This central blower control is therefore quite
distinct from the secondary Cabin Control
systems where the <AIR CONTROL> digital
display only operates the blower(s) of the
cabin where the display is situated without
any direct link to the main condensing unit.
Any blowers directly connected to the TECC
controller card will be activated after the
cycle LED comes on. However blowers will
only become active if the chilled water tem-
perature is compatible with the enteredset-
point.
If blower operation cannot be activated the
error code <bA11> will flash briefly and then
remain visible when accessing blower con-
trol through F/Blower key.
(See also here-after list of error codes).
Blower operation will only start after a com-
patibility check with the temperature of the
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 4
chilled water circuit.
Example : in <Cool> mode with a set-point
temperature of 21° C., blower operation will
only start after the temperature of the water
circuit has reached 20° C or less. This avoids
start-up of blower operation with a non com-
patible water circuit temperature.
For these TECC cards it is possible to alto-
gether stop blower operation by choosing the
option <0> after manual blower speed <1>.
This allows to altogether stop blower opera-
tion by the main controller card during the
night for example while still continuing to
operate the chiller unit for the rest of the
ship’s air-handlers.
With the <CHILLER CONTROL>, blower
control is completely distinct from compres-
sor operation :
1) Blower control will continue even if com-
pressor operation is thermostatically stopped.
2) Compressor operation will continue even
if the blower is thermostatically stopped.
It is not possible however to operate the
blowers in a different cycle from compressor
operation ; for instance : compressors run-
ning in cool cycle and blowers in heat cycle.
In that case compressor operation will have
priority and blower-operation will be stopped
(error code <bA11>).
4. SECONDARY COMMANDS :
The F/Blower key gives immediate access to
commands and displays necessary for day to
day operation. When pushing the F/Blower
key you will see to the left a code which indi-
cates the type of display or command and to
the right the present value.
In order of appearance here-after an explana-
tion of these commands/displays :
a) Blower speed control : < b A>
(0,1,2,3,4,5)
This command preceeded by the letter b
(blower) allows the following settings :
A = automatic blower speed adjusted to tem-
perature differential.
0 = blower stop
1 to 5 = manual Speed Control
Speed control is in real time mode i.e.
changes are effected immediately without
any validation procedure.
Warning : All following func-
tions need validation before a new

value is accepted.
Validation is obtained by pushing
the F/Blower key again and by
going to the next function line.
Then final validation will occur
automatically when the display
goes back to room temperature
read-out or final validation can be
forced by pushing the On/Off key
briefly while still in F mode.
Validation is witnessed by the brief
display of the message <memo>.
b) Read out of chilled water temperature :
<H10.2> (10.2 ° C) - for example.
c) Cycle mode choice : <F 3> (1 to 5)
The following cycle modes can be choosen
manually :
1 = cool cycle only
2 = heat cycle only
3 = automatic cycle switching with reversible
compressor
4 = automatic cycle switching without
reversible compressor
5 = heat cycle only without reversible com-
pressor
d) AC Voltage read-out : < U232>
(232 Volts)
e) Manual on/off Compressor 1 : <1C01>
<1C01> = Compressor 1 on
<1C00> = Compressor 1 off
f) Manual on/off Compressor 2 : <2C01>
<2C01> = on
<2C00> = off
Idem for compressors 3 and 4 - <3C01> and
<4C01>.
g) Start-up Priority Compressors 1 to 4 :
<P123> = 1,2,3,4 ; <P341>=3,4,1,2
<P A> = automatic priority rotation; when
in this priority mode, the starting
order will be changed at every
restart after a thermostatic cut-out.
h) Time delay between compressor start-up :
<L 9> (9 seconds) - programmable
from 1 and 9 seconds.
i) Individual thermostatic advance compres-
sors 1 to 4. In relation to the general chilled
water temperature set-point, it is possible to
differenciate the cut-out temperature for
each compressor.
Factory default setting : <1L0.0> etc
<2L1.2> means compressor 2 will cut out
1.2° before the general set-point value. So
for a general value of 4°, compressor 2 will
cut out at 4 + 1.2 = 5.2 °.
Same is possible for the other compressors.
EDITION DATED 21ST AUGUST 2006
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2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 5
peratures (below 8° C approx.).
j) Automatic dehumidification while absent.
factory default setting : <d 0> <A02> : HP (high pressure) cut-out - com-
0 = non active pressor 1 - probable causes :
1 = 1 cycle per 24H - insufficient or non-existent sea-
2 = 2 cycles per 24H etc water cooling - check sea-water
pump.
k) Display time of secondary functions (F/ - insufficient or interrupted water
Blower key) by periods of 20 seconds. flow in chiller circuit when operat-
<t 1> (factory default setting) = display ing in heat cycle.
time 20 seconds. - too much refrigerant in system -
call a specialist
4. VISUAL ERROR CODES - - abnormal sea water temperature
DIGITAL DISPLAY conditions in heat cycle (sea-water
temperatures above 20° C approx.)
The following malfunctions will be dis-
<A03> : BP cut-out - compressor 2 - for
played directly on the digital display by a
probable causes see <A01>
code and will be followed by a system halt
(except for <bA11> - see hereafter).
<A04> : HP cut-out - compressor 2 - for
probable causes see <A02>
Whenever any of these codes appear the sys-
tem is stopped for approx. 60 seconds and
<A05> to <A08> - same as above for com-
then a re-start is attempted.
pressors 3 and 4 (if present).
If for more than 30 minutes the same mal-
If any of these error codes appear too fre-
function occurs, the system will be stopped
quently and no appropriate action can be
completely and the error-code will become
taken with the available means on board, it is
steady.
necessary to call a specialist.
No more re-starts will be attempted and the
Do not insist with manual re-starts in such
user will have to re-set the system by pushing
cases as this may cause major damage to the
the On/Off key or by temporarily cutting off
principal components (compressors, pumps,
the AC supply to the system.
etc).
List of error-codes and nature of malfunc-
<A09> - absent or defective external air sen-
tion :
sor.
Code <AAA> :
<A10> - absent or defective chilled water
Persistent low voltage (voltage below 195V)
sensor.
for more than 5 seconds - (see also hereafter
- Trouble-Shooting - Page 19).
<bA11> - blower operation from TECC card
impossible because of non-compati-
Code A01 to A08 :
ble water temperature versus pro-
Pressure safety cut-out of compressors 1 to 4.
grammed set-point. This is the only
The HP(High Pressure) and BP(Low
error code which will not result in
Pressure) safety switches are directly con-
a complete system halt.
trolled by the micro-processor inclusing the
time-delays for re-start, etc.
<CA11> - all compressors are disactivated
by soft - through F/Blower key : <1C00>,
Error codes displayed and probable nature of
<2C00>, etc.
anomaly.
To reactivate re-program as follows :
<A01> : BP (low pressure) cut-out - com-
<1C01>, <2C01>, etc
pressor 1 - probable causes :
- interrupted or insufficient water-
flow in chiller circuit
- sea-water circulation deficient
when running in heat cycle mode
- insufficient refrigerant charging
level
- abnormal sea-water temperature
conditions in heat cycle (sea-water
temperatures under 6° C. approx.)
- first start-up in heat cycle with
very low chilled water circuit tem-
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 5
 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 6

5 - DIGITAL CABIN BLOWER CONTROL - GENERAL PRINCIPLES

4 8
BASIC COMMANDS :
1 - Press to turn on - press again to turn off.
2 - Press to read set-point temperature - hold to raise
5 set-point temperature.
3 - Press to read set-point temperature - hold to lower
set-point temperature.
4 - Led indicating system working in cool mode
6
5 - Led indicating manual blower speed control is active
6 - Led indicating system working in heat mode
7 - Function/Blower Key - immediate access to : * Default Values
1 - chilled water temperature read-out ....................... *H13.2
- automatic dehumidification cycle during absence *d 0
- display time secondary functions accessible by *t 2
F/Blower key
8 - blower speed control ............................................. *b A
2
7 3
9 - Push Both Keys
9 - Access to hidden programming functions - see page 7.
Simultaneously
after Display Extinction
Individual cabins controlled by WEBASTO ature at air-handler entry :
Digital Cabin Controls are completely inde- Danfoss/Lizhan 3-way solenoid valve sys-
pendent from the central condensing unit i.e. All Cabin Controls allow the user to immedi- tems, where the water-flow is completely
there is no direct electrical or electronic link ately visualize the water-circuit temperature halted when set-point temperature is reached
between the cabin control unit and the central at the entry of the cabin’s air-handler. (push and the flow returned directly to the return-
TECC controller. F/Blower key - see also drawing here-above). line through a nozzle.

The chilled water temperature sensor allows
the Cabin Control to ascertain which cycle
(heat or cool) is presently valid.
A Cabin Control can be operated entirely
independently from the main condensing unit
i.e. :
- it can be switched off or turned on at any
time by the end-user
- the end-user can set any temperature set-
point as long as it is compatible with
the general operation mode valid (heat or
cool)
- blower operation can be individually con-
trolled and programmed
This feature allows the user to ascertain that
water-circulation is normal through the air-
handler without abnormal differences as
compared with the condensing unit water
exit. (Normally temperature rise between
condensing unit exit and air-handler entry
should not exceed approx. 4° C.) Before get-
ting worried however, the first thing to check
is the proper attachment of the cabin control
water temperature sensor to the air-handler
entry and its proper insulation from outside
interference.
5A - DIGTAL CABIN CONTROL -
TYPE CAB - 230V - 2000 SERIES
When using 3-way valves it is possible to
adopt continuous blower operation.
See page 7 - drawing N° 5.1 for full
schematics.
Secondary Commands - <F> key :
The <F> key gives immediate access to com-
mands and displays necessary for day to day
operation. When pushing the F key you will
see to the left a code which indicates the type
of display or command and to the right the
present value.

2) Flashing of Error Code <bA11> :
If the user programs a set-point temperature
incompatible with the general water circuit
temperature as presently available (for exam-
ple : set-point requested : 20° C for a room
temperature of 25° C and a water-circuit tem-
perature of 35° C) = Cool cycle requested
with the chilled water circuit obviously
working in heat cycle.
Blower operation will be stopped and error
code <bA11> will blink for approx. 10 sec-
onds.
After that the error code will still be visible
when accessing blower control by the F key.
The error code will disappear and normal
blower operation will resume as soon as the
water circuit temperature drops below 20° C.
Direct read-out of water-circuit temper-
EDITION DATED 21ST AUGUST 2006
This is the most common type of digital
cabin control and includes :
- digital display <AIR CONTROL>
- CAB - 230V controller card in plastic box
- 4 ml display cable
- 2.5 ml chilled water temperature cable
- 4 ml air temperature sensor (optional)
The digital display <AIR CONTROL>
includes an air temp. sensor housed behind
the 2 small openings on the front panel. It is
sometimes necessary however to use the
optional external air-sensor if for instance the
digital display is subject to direct heat induc-
tion (sun-rays, instruments from behind, etc)
All CAB controls include an outlet for sole-
noid water valve control on the entry of the
air-handler.
Solenoid valve control are an optional extra :
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 6
In order of appearance here-after an explana-
tion of these commands/displays :
a) Blower speed control : <b A>
(0,1,2,3,4,5)
This function is also accessible directly
through the dedicated Blower key.
This command preceeded by the letter b
(blower) allows the following settings :
A = automatic blower speed adjusted to tem-
perature differential.
0 = blower stop
1 to 5 = Manual Speed Control
Speed control is in real time mode i.e.
changes are effective immediately without
any validation procedure.
b) Read out of chilled water temp. :

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5.1 - ELECTRICAL AND OTHER CONNECTIONS - CABv3 - 230V - DIGITAL CABIN CONTROL
Chilled Water sensor to be fixed on chilled water entry of Air-handler
<h10.2> (10.2 ° C) - example.
c) Control of external heat-source.
<F 1> = normal auto-reverse cycle
(cool/heat) without external heat source.
<F 2> = autoreverse cycle operation with
external heat assistance. In that case the oulet
connectors <HEAT> on the Cabin controller
card are activated together with the
<VALVE> oultlet when heat cycle is select-
ed. This external heat source can be an AC
heating element or any other source such as
ceramic heaters etc
<F 3> = heat operation with external heat
source only. Inthat case the <VALVE> outlet
on the controller card is not activated and
only the <HEAT> connectors are opera-
tional.
c) Automatic dehumidification while
absent.
Factory default setting : <d 0>
0 = non active
1 = 1 cycle per 24H
2 = 2 cycles per 24H etc
d) display time of secondary functions
(F/Blower key) by periods of 20 seconds.
Factory default setting : <t 1> = display
time 20 seconds
Special features - 2000/2004 Series :
See beginning page 4.
Continued features - 2000 Series :
A) Automatic blank/sleep mode - program-
mable time delay. Factory default : 15 min-
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2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 7
BROWN
BLACK
utes. While in blank/sleep mode the cycle
LED flashes discretely every 20 seconds. To
go back to normal operation push any key.
B) Real time modification of all blower
speed settings.
It is now possible to alter all speed settings (1
to 5) before actually putting the system into
service. To do so entrer programming mode
with set-point at 15° C.; proceed to line<6> =
speed 5 (max).
Alter value and blower speed will immedi-
ately change in real time. When satisfied go
to following line <7> = speed 4 and do the
same.
Proceed until lowest speed N° 1 and go back
again to speed N° 5 if not satisfied.
When all speeds are programmed according
to need, validate by pushing on/off key
(<memo> will be displayed briefly).
Attention : Never program speeds so
low that the blower is in danger of
stopping or will not re-start at that
setting. This will inevitably entail
motor-windings burn-out and will
not be covered by WEBASTO war-
ranty.
Programming of the CAB - 230V
controller cards :
To access hidden programming functions
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 7
BLUE
3 x 1 mm²
raise set-point temperature to 29° or lower to
15° and push On/Off key.
Then push both set-point keys simultaneous-
ly for approx. 3 seconds and you will enter
programming mode as explained here-after.
Validation is obtained by pushing the
F/Blower key and by going to the next pro-
gramming line.
Programming codes available by raising the
set-point to 29° C :
Code <4> : Calibration of chilled water temp
Code <5> : time delay in minutes before the
display goes into sleep mode.
Code <7> : Calibration of room temperature
read-out.
Code <b> : Program version
Programming codes available when lowering
the set-point to 15° C :
Code <1> - factory setting : 0 - infra-red
remote control :
0 = infra-red remote control disabled
1 = infra-red remote control active
Code <2> : Blower type : Centrifugal or
Cross-Flow. Factory default : 1
0 = centrifugal blowers only
1 = centrifugal + cross-flow
Code <3> : continuous blower operation = 1
thermostatic blower control = 0
Code <4> : integrated air-sensor = 1
external air-sensor = 0
Code <5> : display in Celsius or Fahrenheit
default value = 0
0 = Celsius read-out
1 = Fahrenheit read-out
Code <6> : calibration speed N° 5 (max)
 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 8
Code <7> : idem speed N° 4 PLANA (VIMAR) MECHANICAL THERMOSTAT + 3 SPEED BLOWER CONTROL
Code <8> : idem speed N° 3 Display Cable 4.5 ml
Code <9> : idem speed N° 2 Thermostat
Knob
Code <A> : idem speed N° 1
Code <c> : duration heat cycle dehumidifi-
cation mode in minutes.
Code <d> : duration cool cycle dehumidifi-
cation mode in minutes.

5D - MTH - MECHANICAL THER-

Blower Speed
MOSTAT Knob (0 + 3)
The MTH thermostat has a knob control for Heat/Cool
Selector +
setting the desired set-point temperature and
On/Off
a selector to switch between summer and Selector
winter operation. 3 Speed Controller
See here-after the electrical schematics of
MTH installation. WIRING DIAGRAM - PLANA THERMOSTAT + 3 SPEED CONTROL
Brown 22 12 NC

5E - MTH2 - MECHANICAL THER- LIZHAN / ZHONGLI

3-WAY VALVE
21 11 COM

MOSTAT + 3 SPEED CONTROL Black 24 14 NO

12A
ZL RELAY
The MTH2 mechanical thermostat incorpo- A B
C NC NO N L
rates a 3 position selector which can be AB
ELECTRONIC VIMAR/PLANA THERMOSTAT
linked to a simple 3 speed blower control Blue A2 A1

system.
See here-after (Photo 5.6) for the compo-
nents included in this system. The assembly 230V BOAT SUPPLY

is delivered with a multi-conductor plug to

MTH - MECHANICAL THERMO-
STAT - CABIN BLOWER CONTROL
AIRHANDLER BLOWER

SUMMER/WINTER SELECTOR

avoid cabling errors.

5F - PLANA (Vimar) 3 speed

Thermostats

Based on the modular Plana series by

Vimar with the same features as 5E.
SET-POINT ADJUSTMENT KNOB

5.6 - WIRING DIAGRAM - MTH BELUX THERMOSTAT + 3 SPEED BLOWER CONTROL

Brown 22 12 NC

21 11 COM
LIZHAN / ZHONGLI
3-WAY VALVE
Black 24 14 NO
Heat/Cool Selector
On/Off
RELAY
12A
Switch
A
ZL 3
B
4

AB
Blue A2 A1

3 Speed
Selector
230V BOAT SUPPLY

AIRHANDLER BLOWER

WEBASTO 3 SPEED
Controller Card

WEBASTO PREWIRED RJ45 CABLE

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 8

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 9

6 - PROGRAMMABLE FUNCTIONS - CHILLER CONTROL

To access the programmable parameters of
the TECC electronic controller proceed as
following :
Raise set-point temperature to the max. i.e.
29° Centigrade. Then turn off system by
pressing the <On/Off> key.
Press simultaneously the 2 set-point keys for
aprox. 3 seconds until you see to the left of
6.1 - DIGITAL DISPLAY <CHILLER CONTROL> - PROGRAMMING ACCESS
15
gives the re-start point of the compressor(s)
after a thermostatic interruption (in cool
cycle).
Adjustment range : between 2°C and +18°C.
Code <2> - factory setting : 40° C. higher
set-point temperature of the chilled water cir-
cuit when in heat cycle. This value gives the
cut-out point of the compressor(s) when
functioning in heat cycle.
Set-point temperature adjustable between
30° and 55° C.
Code <3> -factory setting : 37° C. - lower
set-point temperature of the chiller water cir-
16
PROGRAMMING MODE :
Code <9> - pre-programmed value : 0 -
Functioning principle of staging relay :
Value 0 : the relay functions as a staging
relay (see also page 25)
Value 1 : the relay functions as the outlet con-
trol for a soleniod valve system for the air-
handlers directly controlled by the main
TECC controller.
Value 2 : the relay functions as a witness for
a system halt and general alarm (A01, A02,
A09, etc) :
- contacts closed between C2 and R2 or con-
tacts open between C2 and T2 = no alarm

To enter programming mode : raise or lower set-point to 29 or 15° C.

Turn off system by pressing <Power> key - 14.

Press simultaneously keys <11>. The display will show to the left
<15>, the number code of the current programming line and to the right
<16> the present value.

To validate and memorize modified parameters press the <F> key (12)
and proceed to the following programming line.

14 12 11

the digital display a single number code indi-
cating the programming line presently valid
and to the right a single ou double read-out
indicating the present programming value.
To go to the next programming line (left sin-
gle number), press <F> key.
If you modify the programming value (to the
right of the display), you need to validate the
changes made by pressing the <F> key and
go to the next programming line. This step
will validate and memorize the changes
made.
Here-after the explanations regarding the
available programmable functions :
1° Functions accessible by raising the set-
point to 29° C. :
Code <0> - factory setting : +4° Celsius -
lower set-point temperature of the chilled
water circuit when in cool cycle. This value
gives the compressor cut-out point when in
cool cycle.
Adjustment range : between 0°C and +15°C.
Code <1> - factory setting : +7° Celsius -
higher set-point temperature of the chilled
water circuit when in cool cycle. This value
EDITION DATED 21ST AUGUST 2006
cuit when in heat cycle. This value gives the
re-start point of the compressor(s) after a
thermostatic interruption (in heat cycle).
Set-point temperature adjustable between
27° and 52° C.
Code <4> - pre-programmed value : 0 - cali-
bration of the chilled water circuit tempera-
ture - possible adjustment between -9° and
+9° C.
Code <5> - factory setting : 15 - time delay
in minutes before the digital display goes
into blank/sleep mode. Cycle LED flashes
discretely to indicate system is operational.
Code <6> - factory setting : 1 - first start up
delay in seconds after connecting AC supply.
Adjustable between 1 and 20 seconds.
Code <7> - factory setting : 0 - calibration
of room temperature read-out. Correction
between +9 and -9° C.
Code <8> - pre-programmed value : 0.
Factory calibration of AC voltage 50 Hz as
displayed on the digital panel when access-
ing the secondary commands - F/Blower key.
Correction between -20 and +20 Volt.
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 9
- contacts open between C2 and R2 or con-
tacts closed between C2 and T2 : general
alarm and system halt.
Value 3 : cycle indication
- contacts closed between C2 and T2 = heat
cycle
- contacts closed between C2 and R2 = cool
cycle
System Halt : contacts closed between C2
and R2.
Code <A> - pre-programmed value : -10.
Factory calibration of AC voltage 60 Hz as
displayed on the digital panel when access-
ing the secondary commands - F/Blower key.
Correction between -30 and +20 Volt
Code <b> - Program version
Re-intializing the factory default set-
tings :
It is possible to force the program to re-ini-
tialize all program values to factory default
settings by the following procedure :
When reading the <b> line as above (through
the 29° set-point), push the <sun> key until
the program version starts to flash. Keep the
<sun> key pushed down until the display
shows <init>.

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 10
Leave programming mode by pushing
<On/Off> key - you are now back to the fac-
tory default settings.
2° Functions accessible when lowering
the set-point temperature to 15° C :
Code <0> - pre-programmed value :195 -
low AC voltage cut-out value.
Time delay is 5 seconds approx. i.e. the low
voltage situation will have to persist during
more than 5 seconds before cut-out occurs.
After a cut-out the electronic controller resets
and will start a new cycle. So a renewed
attempt to start the compressor will occur
after approx. 90 seconds.
During low-voltage cut-out the display panel
will show the 3 letters <AAA>.
Programming of a cut-out level below 195 V
is done at the entire risk of the operator. It
should be noted that almost all compressor
manufacturers decline all responsibility for
defects resulting from operating the com-
pressors below 195V AC.
Code <1> - factory setting : 0 - infra-red
remote control :
0 = infra-red remote control disabled
1 = infra-red remote control active
Code <2> - factory setting : 0 - choice of
small relay setting indicating cool/heat cycle
operation or alarm status.
0 = cycle indication :
- contacts closed between C1 and T1 = heat
cycle
- contacts closed between C1 and R1 = cool
cycle
System Halt : contacts closed between C1
and R1.
1 = alarm status : the relay functions as a wit-
ness for a system halt and general alarm
(A01, A02, A09, etc) :
- contacts closed between C1 and R1 or con-
tacts open between C1 and T1 = no alarm
- contacts open between C1 and R1 or con-
tacts closed between C1 and T1 : general
alarm and system halt.
Code <3> - pre-programmed value : 0 -
basic choice of blower control :
0 - thermostatic control of blower operation
i.e. blower operation will be interrupted ther-
mostatically when reaching the appropriate
set-point.
1 - un-interrupted blower operation regard-
less of the thermostatic control.
Code <4> - factory setting : 0 - Choice
between integrated air sensor and external air
sensor :
EDITION DATED 21ST AUGUST 2006
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1 - air sensor integrated in digital display
0 - external air sensor 2) TECC controller for 3 or 4 compressors,
with secondary card for compr. 3 and 4 :
Code <5> - Display in Celsius or Fahrenheit
default value = 0 Warning : if dipswitches are not set
0 = display in Celsius according to the above configurations i.e.
1 = display in Fahrenheit according to the number of compressors
effectively on line, the TECC controller card
Code <6> : modification speed N° 5 (max) may behave in an unpredictable manner :
Code <7> : idem speed N° 4
Code <8> : idem speed N° 3 - the initialisation <init> can not be complet-
Code <9> : idem speed N° 2 ed - card remains blocked on start-up.
Code <A> : idem speed N° 1
- HP/BP alarms for non-existing compres-
Code <b> - factory setting : 0 - access code sors.
value for programming mode.
0 = no access code required Etc.
1 to 99 = access code activated
In case you can’t remember your access code
you can gain access to the concerned pro-
gramming line by typing in the factory
access code : 64
Code <c> - factory setting : 1 - duration in
minutes of heat cycle operation under the
dehumidifying procedure.
Code <d> - factory setting : 1 - duration in
minutes of cool cycle operation under the
dehumidifying procedure.
DIPSWITCHES :
The TECC controller card has a dipswitch
arrangement which should be set and main-
tained according to the following settings :
ATT. DIPSWITCH SETTINGS
BLACK = PUSHED DOWN
1 2 3 4
OPEN
1) TECC controller for compressors 1 and 2
only, without the secondary card for com-
pressors 3 and 4 :
ATT. DIPSWITCH SETTINGS
BLACK = PUSHED DOWN
1 2 3 4
OPEN
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 10
 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 11

7 - PRACTICAL INSTALLATION OF COMPONENTS - GUIDELINES

7A) SEA WATER COOLING
Install the pump/strainer assembly in such a
manner that a natural gentle upwards slope
exists from the sea-cock to the pump itself.
See also drawing hereafter - ref. 7.1
It is strongly recommended to install an air-
bleeder system immediately at the discharge
outlet of the pump. The advice is especially
valid for pumps CLD125/250/350/1000/
1500 and 2000. The CLD2500 and higher
generally will not require a bleeder system to
This will allow easy priming of the circuit
and also calibration of the sea-water flow for
each air-conditioning unit in case of imbal-
ance in the water tubing lengths.
7B) AIR-HANDLER COILS :
The finned coils of the evaporators and/or
air-handlers are fragile. When during instal-
lation the fins of these coils are damaged,
take care to re-align the fins in order not to
impair proper air-flow.
with sufficiently strong steel or plastic re-
inforcement. Do not restrict air-flow by
bending the air-ducts too tightly or by acci-
dental local deformation.
Do not install air-ducts of excessive lengths
(+ 2.5 ml); the pressure loss and consequent
reduction of air-flow will seriously diminish
the efficiency of the installation.
If long ducts are an absolute necessity, try to
use rigid PVC piping of equal diameter and
the associated elbows, etc.

7.1 - INSTALLATION OF SEAWATER COOLING PUMP AND PIPING

TO OVER-BOARD OUTLET APPROX. 10 CMS ABOVE WATER-LINE

NB - ALL PIPING AS SHORT AS POSSIBLE WITHOUT

KINKS NOR SYPHONS

WATER-LINE

INSTALLATION OF BLEEDER ADVISABLE

SUCTION GENTLY UPWARDS TO

PUMPS SITUATED
FACILITATE PRIMING
AT LEAST 25 CMS BELOW WATER-LINE

SEA-WATER STRAINER

CLAM-SHELL TYPE THRU-HULL FITTING

WITH SLOTS DIRECTED TOWARDS BOW TO OBTAIN POSITIVE PRESSURE IN SECTION LINE

ensure proper operation.
For ALL boats it is strongly recommended to
install a water-scoop at the entry of the sea-
cock and directed towards the bow of the
boat so that at speed positive pressure builds
up in the supply line to the sea-water pump.
Sea-water cooling exits :
Provide for a separate sea-water exit for each
air-conditioning unit installed even if only
one pump provides cooling for all units.
Return air should be filtered to avoid accu- PVC piping because of its smooth interior
mulation of dust on the coil fins. induces far less friction then standard steel
wire re-inforced flexible ducting.
This can be obtained by 2 means :
a) Install WEBASTO supplied return air
grilles which include a filter element behind
the grilles.
b) Install a filtering element just in front of
the return air coil surface. Such filter mate-
rial can be also obtained from WEBASTO
Marine.

Introduce shut-off valves for each unit if 1 7C) AIR-DUCTS :

pump provides cooling for more than 1 air-
conditioning unit. Flexible air-ducts need to be of good quality

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 12

8 - CHILLED WATER SYSTEM INSTALLATION

8A) PRESSURIZED/NON PRESSUR-
IZED SYSTEMS :
Chilled water circuit can be static non-pres-
surized or pressurized with membrane type
expansion-tanks.
If the system adopted is static, the expansion
tank should be the highest point of the circuit
while taking into consideration the possible
heeling angle under sail.
Expansion tanks should always be connected
to the suction side of the circulation pump.
Cabin Control, it is not necessary to provide
for other entry valves.
8C) WATER CIRCUIT TEMPERATURE
SENSORS :
To obtain a satisfactorily working system it is
of utmost importance that the water-circuit
temperature sensors are correctly placed
accordingly to WEBASTO specifications.
In order to exclude any erroneous tempera-
ture pick-up, WEBASTO provides specific
locations on its condensing units.
rator meet. The sensor should be properly
insulated against external infuence.
All TWIN-CI units delivered by WEBASTO
come with the sensor already fixed in the
proper location.
8H) ADDED HEAT-EXCHANGERS
The TECC controller card allows to add
heat-exchangers in the chilled water circuit
which can be of all nature :
1) Water/Water exchanger to use the 85/90°
C hot water circulation from a fuel heater

8B) FREE FLOW VERSUS SOLENOID
VALVE CONTROL :
The water-circuit can be free-flow where the
water-flow is continuous through all air-han-
dlers and thermostatic control for each air-
handler is obtained by stopping blower oper-
ation.
In this case it is advisable to introduce man-
ual ball-valves on each of the air-handler
entries so as to enable balancing out of the
water-flow if necessary.
In case of a solenoid valve system where
each air-handler is equipped with a electrical
solenoid valve controlled by the WEBASTO
8.1 - SCHEMATICS - INSTALLATION AND CONNECTION OF WEBASTO HEAT EXCHANGER
These points are short tubular housings 2) Electrical calorifiers
which cross the chilled water outlets at the
following locations : 3) Engine heat
Single Evaporator Chiller Units : Etc
Exit temperature sensor : the water-circuit Here-after (Drawing N° 8.1) an example of a
exit on each evaporator is provided with a Water/Water exchanger specially adapted for
tubular transverse housing where this tem- Webasto fuel heaters .
perature sensor should be placed.
Twin Evaporator Chiller Units (TWIN/CI):
For TWIN-CI modules with 2 compressors
on 1 tray and independent evaporators, the
chilled water sensor is attached to the Tee
junction where the 2 exit pipes of the evapo-

CONNECT TO <VALVE> OUTLETS

2 POLE ELECTRICAL WIRE
ON TECC CONTROLLER CARD
2 POLE ELECTRICAL WIRE

SPECIAL MARINE 3-WAY VALVE

ASSEMBLY

CHILLED WATER CIRCUIT OUT

75/85˚ C WATER FROM FUEL HEATER

RETURN LINE TO FUEL HEATER

CHILLED WATER CIRCUIT IN
DIRECTLY FROM CHIILER PUMP

RETURN TO FUEL HEATER

MARINE EXCHANGER
REF. WBCL005080 OR WBCL005081

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 13

CHILLED WATER CIRCUIT PIPING

GOLDEN RULES - INSTALLATION OF BASIC COMPONENTS
Here-after a summary of the most basic but important guide-lines for success when installing a Chiller piping
System. These Guide-lines cover all items such as insulation, water-piping, etc
Most important pre-liminary remark :
Water-flow rates in a Chiller circulation circuit are approx. 2/3 times as high as the normal flow rates found
a central heating system at home. So pay special attention to all possible flow restrictions !
8E - CHILLED WATER PIPING 8.2 - ELBOWS 90° - CHILLED WATER PIPING radius. Short radius elbows entail a flow-
AND ACCESSORIES rate loss of approx. 2.5% per elbow. A suc-
cession of 8 short radius elbows will there-
Chilled water piping can be in rigid plastic SHORT RADIUS ELBOW fore result in total flow-rate reduction of
tubing and/or flexible reinforced hoses. 100% x0.975x0.975x0.975x0.975 etc =
81.66%.
Internal dimensions of tubing should be in
conformity with piping drawing as sup- Large radius elbows only result in a flow-
plied by WEBASTO. rate loss of approx. 0.5%.

PAY SPECIAL ATTENTION TO : If no large radius elbows can be found use

USE LARGE RADIUS
2 successive 45° elbows instead.
ELBOW ONLY OR 2 X
1) ELBOWS 45° ELBOWS
Only use large radius elbows and not short See also photo to the left.
EXPANSION TANK : If 8.3 - EXAMPLE WATER PIPING CIRCUIT - 1 CHILLER UNIT + 4 AIR-HANDLERS
static- should be highest
part of circuit

SHUT-OFF VALVES ON ENTRY AND EXIT

FOR EASY MAINTENANCE

= SHUT-OFF VALVE

OPTIONAL RETURN LINE VALVE

LARGE RADIUS ELBOWS ONLY

Secondary access with shut-

off valve 3/4” - should
always face upwards

CIRCULATION PUMP

If this line always goes upwards without any down-turn, it can be

used for filling the system ; if not use secondary access and attach Drain valve at lowest part of circuit. Allows full draining of the sys-
temporary filling hose with temporary filling tank on rooftop, up tem after initial pressure tests and also in case of doubt concerning
and above highest air-handler. Diam. 5/8” or 3/4” transparent. the exact glycol (anti-freeze) percentage of the mixture.

2) PIPE INSULATION FOAM THICKNESS : 9 MM FOR

BOATS UP TO 15/16 M; 13 MM ONLY USE RUBBER OR SYNTHETIC
FOR BOATS OVER 16 ML. RUBBER FOAM INSULATION
Only use rubber or synthetic rubber foam
insulation (Armstrong Armaflex or
Rubatex or similar) - do not use polythene
foam insulation.

Do not use split-type open insulation as

this type tends to come apart after a certain
time.

Try to use rigid foam core supports to fix

piping.
RIGID CORE SPECIAL SUPPORT
See also photo to the right. ENABLING SOLID FIXING OF TUB-
ING WITHOUT DEFORMATION
8.4 - TUBING INSULATION
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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 14
Insulation foam thickness should be at during the winter and also freezing up of the
least 9 mm for boats up to 15/16 ml and 13 condensing unit evaporator(s) should for any
mm for all boats above that length. reason the temperature control fail or be
retarded.
Finish off all Tee junstions and others with
self-adhesive foam tape. There is a general safety cut-out when freez-
ing up an evaporator by means of the Low
3) TEE JUNCTIONS
Pressure cut-out, but this safety device may
allow a temporary drop of the water-circuit
It is preferable to use oblique Tee junctions
for secondary branching. If 45° Tees are temperature to approx. -2° C before stopping
not available make sure the reduction in the system. Hence the utmost importance of
diam. on the secondary line is made after adding approx. 20% glycol to the water-cir-
the junction Tee so as to obtain the largest cuit.
possible entry diam.
Attention : non-respect of the use of
See photo here-under. glycol/water mixture (25% glycol +
8.5 - TEE JUNCTIONS
75% fresh water) in the chilled
WATER-FLOW - SECONDARY
water circulation circuit will void
any WEBASTO warranty.
45° TEE
JUNCTION 6) FILLING UP AND PURGING OF A
CHILLED WATER CIRCUIT :
The following procedure is the simplest and
most effective way to prepare a chilled water
WATER-FLOW - MAIN BRANCH
circuit, purge it from all air and put it into
operation in the shortest possible time.
LEAVE AMPLE ROOM BEFORE Make sure to follow the steps here-under in
REDUCING PIPE DIAMETER the same order :
1) Installation of purging Tee on entry/suc-
tion side of circulation pump. This Tee
should enable the temporary connection of a
filling hose of at least 15 mm interior diam.
The filling entry should be directed upwards
and not side-ways or down-wards.
Make sure the jerrycan on the roof is at least
half full at that stage.
Start circulation pump shortly for approx. 15
seconds and stop it. You will notice massive
air bubbles going upwards through the filling
hose.
Repeat this for several times until such
moment that the air bubbles going upwards
through the filling hose become small
enough to leave the pump on continuously
without cavitating.
6) Leave the pump on continuously for at
least 45 minutes. You will notice a contiuous
small stream of bulbles going upwards and
solid water going downwards.
7) Help the final purging of the system by
selectively closing the shut-off valves on all
air-handlers so as to force the waterflow
through the other air-handlers. This will fin-
ish purging any residual air that may have
been trapped in any individual air-handler.
8) When the pump is running without any
cavitation noise and no further small air-bub-
bles go upwards from the Tee junction on the
pump entry, stop the circulation pump, close
the shut-off valve and disconnect the tempo-
rary filling station.
9) With this method there is absolutely no
need to purge at each individual air-handler
provided the filling hose has a sufficiently
large diameter and always goes upwards to
the filling tank on the rooftop.

Fit a shut-off valve enabling quick closing of 10) Remark for pressurized systems only
the access point after completing the filling
90° TEE JUNCTION procedure.
WATER-FLOW
After satisfactory purging of all air in the sys-
tem, close valve on Tee entry to the suction
4) ENTRY DIAM. OF AIR-HANDLERS 2) Install a temporary charging recipient (jer- pump with pump running so as to build up
rycan etc) in such a way that this recipient is maximum pressure in the system.
Always respect the minimum entry diam. the highest point of the circuit and that the
of the air-handlers. Secondary piping to the hose from the acces Tee to the jerrycan goes Then if necessary increase pressure by open-
air-handlers should not be less than the always upwards, never horizontally and ing valve to pressurized water system.
prescribed diam. never downwards. It is advisable to use trans-
parent hose from the Tee to the jerrycan. 11) Refilling after leak :
Here-after list of air-handler entry diame-
ters (all diam. are net internal) : 3) Open all bleeders on all air-handlers. Never refill system with fresh water only; be
Model Entry/Exit diam. sure to always maintain glycol mixture of
4) Start filling the circuit from the jerrycan between. 20 and 25% glycol - 75/80% fresh
4000/4500 BTU 12 mm (1/2”)
on the rooftop - watch all bleeder points on water.
6000 BTU 12 mm
all air-handlers. Close all bleeders immedi-
9000 BTU 15 mm (5/8”)
12000 BTU 15 mm ately when solid water comes out. No further
16000 BTU 15 mm bleeding from the air-handlers will be
24000 BTU 20 mm (3/4”) required from there on.

5) ANTI-FREEZE SOLUTION : 5) Isolate the 230V supply to the circulation

It is imperative to add approx. 25% pure gly-
col to the chilled water-circuit system so as to
avoid accidental freezing of the water-circuit
EDITION DATED 21ST AUGUST 2006
pump so as to be able to switch the circula-
tion pump on and off manually. The easiest
method is to connect a temporay lead to the
circulation pump with a manual switch.
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 14

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 15

TYPICAL SCHEMATICAL EXAMPLES OF CHILLED WATER CIRCUITS

Here-after a certain number of examples of typical chilled water circuit piping lay-outs
9. ROUTINE CHECKS
8.6 - EXAMPLE N° 1 - SMALL 18000 BTU CHILLER - CENTRAL LOCATION + 2 AIR-HANDLERS

EXPANSION TANK 18000 BTU

- SHUT-OFF VALVE
D12 = INTERIOR DIAM. 15 MM - 5/8"
D15 = INTERIOR DIAM. 12 MM - 1/2"

D15
D15

AIR-HANDLER AIR-HANDLER
9000 BTU 9000 BTU

CHILLED WATER CIRCULATION

PUMP

D12 D12

D15
D12 D12

8.7 - EXAMPLE N° 2 - MONO-HULL WITH WBCP24/D - STERN LOCATION + 4 AIR-HANDLERS

1 = 24000 BTU
6 2 = AIR-HANDLER 12000 BTU - SALOON
3 = AIR-HANDLER 6000 BTU - OWNERS CABIN
4 = AIR-HANDLER 4500 BTU - GUEST CABIN
5 = AIR-HANDLER 4500 BTU - GUEST CABIN
6 = EXPANSION TANK

1 D12 = INTERIOR DIAM. 12 MM - 1/2"

D15 = INTERIOR DIAM. 15 MM - 5/8"
D20 = INTERIOR DIAM. 20 MM - 3/4"
D15

- SHUT-OFF VALVE
D20

D20
D15

2 3 4 5
D12

D12
D12
D15

CHILLED WATER
CIRCULATION PUMP
D12

D12

D12
D15

D20 D15

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 15

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 8
4 6
D12 D12

D12 D12

D15
3

EDITION DATED 21ST AUGUST 2006

- SHUT-OFF VALVE

D15
1 = CHILLED WATER CIRCULATION PUMP

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2 = 12000 BTU AIR-HANDLER - MAIN SALOON

D15
3 = 12000 BTU AIR-HANDLER - MAIN SALOON D15
D20
4 = 6000 BTU CABIN AIR-HANDLER
5 = 6000 BTU CABIN AIR-HANDLER 1 36000 BTU
6 = 6000 BTU CABIN AIR-HANDLER
7 = 6000 BTU CABIN AIR-HANDLER
8 = EXPANSION TANK
9 = RETURN COLLECTOR 4 + 1

D15
D12 = INTERIOR DIAM. 12 MM - 1/2" 9
D15 = INTERIOR DIAM. 15 MM - 5/8"
D20 = INTERIOR DIAM. 20 MM - 3/4"

D15
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 16

D20 D20

2
D15

D20
D15

FLOW CALIBRATION VALVES

D15

5 7
D15

D12 D12
D12 D12
8.8 - EXAMPLE N° 3 - CATAMARAN WITH WBCP36/D - CENTRAL LOCATION + 6 AIR-HANDLERS

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 16

 1 = 72000 BTU
2 = EXPANSION TANK
3 = CHILLED WATER CIRCULATION PUMP
2 4 = 16000 BTU AIR-HANDLER - WHEELHOUSE
5 = 16000 BTU AIR-HANDLER - MAIN SALOON

EDITION DATED 21ST AUGUST 2006

6 = 12000 BTU AIR-HANDLER - OWNERS CABIN
7 = 9000 BTU AIR-HANDLER - GUEST CABIN N˚1

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8 = 9000 BTU AIR-HANDLER - GUEST CABIN N˚ 2
9 = 6000 BTU AIR-HANDLER - GUEST CABIN N˚ 3
1 10 = 6000 BTU AIR-HANDLER - GUEST CABIN N˚4

D12 = INTERIOR DIAM. 12 MM - 1/2" - SHUT-OFF VALVE

D15 = INTERIOR DIAM. 15 MM - 5/8"

D20
D20 = INTERIOR DIAM. 20 MM - 3/4" SOLENOID VALVE WITH

D20
D20 D25 = INTERIOR DIAM. 25 MM - 1" METERED BY-PASS
D20 D25 D20

D25

D15
LENGTHS TO COMMON
EXIT AND ENTRY SHOULD
BE BALANCED 4 5 6 7 8 9 10
3
D12

D15
D15
D12
D12

D12

D15
8.9 - EXAMPLE N° 4 - M/Y WITH WBCP72/D TWIN - STERN LOCATION + 10 AIR-HANDLERS

D25 D25 D20

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 17

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 17

 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 18

8F - AIR DUCTING - VENTILA- Also the size of the transition boxe behind maximum possible length to obtain max.
the supply air-grille is important. interior smoothness.
TION See table here-under to choose correct grille For very long duct sections preference should
sections according to BTU rating. be given to rigid ducts (in PVC for example)
1) MINIMUM AIR-GRILLE SEC- which offer a far greater smoothness than
TIONS 2) DUCT TYPE flexible spiral type ducting and therefore will
greatly reduce internal friction.
In order to obtain an acceptable noise level at Flexible air-ducts should be of high quality
max. blower speed certain requirements as with sufficiently strong steel spiral re- For very short lengths non-insulated ducts
regards grille and ducts sections should be inforcement to avoid accidental crushing. may possibly be used. Over greater lengths it
observed. is advisable to use insulted type ducts to
Spiral type ducts should be extended to their avoid condensation on the outside of the air-
ducts.
AIR/HANDLER-WBCC SUPPLY AIR GRILLE RETURN AIR GRILLE DUCT DIAM. DUCT DIAM.
MODEL MODEL/ SECTION cm² MODEL/SECTION cm² <1.8 M DUCT LEN. >1.8 M DUCT LEN.
4000/4500 BTU 1 x 8x4” 150 cm² 1 x 12x5” 325 cm² 80 mm 100 mm
6000 BTU 1 x 10x4” 190 cm² 1 x 11x8” 490 cm² 100 mm 125 mm
9000 BTU 1 x 12x4” 235 cm² 1 x 11x8” 490 cm² 100 mm 125 mm
12000 BTU 1 x 10x5” 250 cm² 1 x 14x7” 550 cm² or 125 mm 150 mm
16000 BTU or 1 x 12x6” 390 cm² 1 x 14x10” 800 cm2 125 mm 150 mm
16000 BTU 2 x 10x4” 380 cm² 125 mm 150 mm
24000 BTU 2 x 10x5” 500 cm² 1 x 14x12” 1000 cm² 2 x 125 mm 2 x 150 mm
32000 BTU 2 x 12x5” 650 cm² 2 x 14x10” 1600 cm² 2 x 125 mm 2 x 150 mm

NB : For duct lengths over 1.80 ml, it may be possible to use the nominal duct diameter (for example 100 mm - 6000 BTU
model), if instead of spiral type flexible ducts, rigid perfectly smooth interior ducts are used.
8.10 - ROTATABLE BLOWER OUTLETS BLOWER ROTATED TO
3) BLOWER OUTLETS MINIMZE FRICTON LOSSES

90° turns with flexible ducts directly from AIR FLOW

blower outlets should be avoided at all costs
as they introduce severe restrictions in the
air-flow. 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. This facility should be used
whenever possible.

See also drawing to the right.

4) TRANSITION BOXES 8.11 - TRANSITION BOX INFORMATION Deflection curve for longitudinal
entry transition boxes
Transition boxes behind supply air-grilles
essentially serve the following purpose :
H
Serve as an expansion volume for the air- H
flow to be reduced in velocity and therefore
reduce air noise when crossing the outlet
louvres.

It follows therefore that the depth of the tran-

sition box is an important factor to allow dis- DUCT DIAM. MINIMUM VALUE OF “H”
persion of the air-flow 80 mm 100 mm
100 mm 120 mm
The table to the right gives the necessary 125 mm 140 mm
information as to the minimum dimensions 150 mm 165 mm
advisable for such transition boxes.
Always try to offset the grille so as to chi-
cane the return air to the coil inlet.
5) RETURN GRILLE OFFSET
This will lower direct noise propagation in a
It is best to avoid placing a return air grille
significant manner.
directly opposite the finned coil surface of an
air-handler. This will inevitably allow propa-
gation of direct blower-motor noise through
the grille.
EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 18

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When starting up an air conditioning unit it is
advisable to carry out a certain number of
control routines to ensure proper functioning
of the unit.
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 19
above points.
5) The compressor works but is subject to
intermittent stops without having attained
the desired set-point temperature.

- always check (especially after a long
absence) the functioning of the sea water
cooling system. Immediately stop the system
if no sea-water comes out of the pump exit
after compressor starts up.
- periodically check the air filter in the return
air grilles. Clean if necessay.
- check condensation drain from the evapora-
tor drain pan.
- take care not to damage the air-ducts. A
damaged air-duct may stop air flow through
the evaporator, freeze up the evaporator and
subsequently damage the compressor.
- when preparing for winter lay-up take care
to rince all sea-water circuits with a fresh-
water/glycol solution (20% or more depend-
ing on local winter conditions).
10.TROUBLE SHOOTING
1) No sign of live : check main electrical sup-
ply, fuses, etc.
2) The digital display shows 3 lettres
<AAA>. This means a persistent state of low
voltage (less than 195 V AC). The system
will re-start as soon as the voltage level
climbs above cut-out level and the system
will then re-start after a time-delay of 1
minute approx.
3) The compressor will start but no sea-water
circulation can be observed :
- the HP and BP (if present) pressure safety
switches stop the compressor because of
abnormal working pressures either on the
high or on the low side. Check proper func-
tioning of the cooling circuit. Check ventila-
tor/blower system for obstructions.
- incorrect freon charge (over-charge or
insufficient charge level).
See also here-above : Error
codes/interrupted system opera-
tion.
6) The heat cycle takes very long to get start-
ed.
- normal if the sea-water temperature is very
low. If sea-water temperature drops below
approx. 8° C. the heat cycle becomes much
less effective and takes long to get properly
started.
7) The heat cycle functions very well but the
compressors stops by means of the high
pressure safety switch.
- the heat cycle functions with a very high
sea-water temperature and therefore the
high pressure side exceeds the safety limit.
You may try to remedy this situation by
slightly restricting the sea-water flow but not
so much as to freeze up the condenser. Do
not forget to open up the sea-water circula-
tion again when switching back to
<COOL>.

- check sea-cock to sea-water pump.

- check sea-water strainer
- check if pump turns
- if the pump does not turn with the com-
pressor working, check power-supply from
the main control unit box to the pump.

4) Compressor and pump work but no correct

operation in either cool or heat cycle :

- during the heat cycle with too slow a sea-

water circulation you may actually freeze up
the sea-water in the cupro-nickel condenser
and completely block the system.

- check voltage level. Do not operate a sys-

tem with a persistent voltage level below
195 V AC.

- check freon charge if operation is still not

satisfactory, after having checked all the
EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 19

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 20

11 - WIRING DIAGRAMS - ALL CHILLER MODELS Page

11.1 - Wiring Diagram single/twin compressor WBCP16/30 - 1 phase ..................................... 21

11.2 - Wiring Diagram Compressors 1 and 2 - 1 or 3 phase .................................................... 22

11.3 - Wiring Diagram Compressors 3 and 4 - 1 or 3 Phase .................................................... 23

11.4 - Wiring schematics -supply cables for TWIN/CI compressor units - single phase .......... 24

11.5 - Wiring schematics - supply cables for TRI/CI (3) compressor units - single phase ...... 24

11.6 - Wiring schematics - supply cables for TRI/CI (3) compressor units - 3 phase .............. 25

11.7 - Wiring schematics - supply cables for QUATRO/CI (4) compressor units - 3 phase ..... 25

11.8 - Wiring Diagram - automatic staging relay - secondary AC loads .................................. 26

11.9 - Wiring Diagram - blower motor running capacitors ....................................................... 26

Minimum Cable Sections per Chiller Model (Ground Wires not shown) :
Model Description Voltage Phase Section mm2
SINGLE COMPRESSOR UNITS
WBCP20 230 1 2 x 2.5 mm2
WBCP24 230 1 2 x 2.5 mm2
WBCP30 230 1 2 x 4 mm2
WBCP36 230 1 2 x 4 mm2
WBCP42 230 1 2 x 6 mm2
WBCP48 230 1 2 x 6 mm2

TWIN COMPRESSOR UNITS (CI models - 2 independent refrigerant circuits)

(Section per Compressor - for single supply line increase section accordingly)
WBCP40/D TWIN 230 1 2 x 2.5 mm2
WBCP52/D TWIN 230 1 2 x 2.5 mm2
WBCP64/D TWIN 230 1 2 x 4 mm2
WBCP72/D TWIN 230 1 2 x 4 mm2
WBCP84/D TWIN 230 1 2 x 6 mm2
WBCP96/D TWIN 230 1 2 x 6 mm2
WBCP84/D TWIN 400 3 3 x 2.5 mm2
WBCP96/D TWIN 400 3 3 x 2.5 mm2

TRI-COMPRESSOR UNITS (CI models - 3/4 independent refrigerant circuits)

(Section per Compressor - for single supply line increase section accordingly)
WBCP108/D TRI 230 1 2 x 4 mm2
WBCP126/D TRI 230 1 2 x 6 mm2
WBCP126/D TRI 400 3 3 x 2.5 mm2
WBCP144/D TRI 230 1 2 x 6 mm2
WBCP144/D TRI 400 3 3 x 2.5 mm2
WBCP180/D TRI 400 3 3 x 4 mm2
WBCP216/D TRI 400 3 3 x 4 mm2
WBCP252/D TRI 400 3 3 x 6 mm2
WBCP288/D QUATRO 400 3 3 x 4 mm2
WBCP336/D QUATRO 400 3 3 x 6 mm2

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 20

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 21

11.1 - 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 11.2 - page 22)

ATT. DIPSWITCH SETTINGS

BLACK = PUSHED DOWN
1 2 3 4
REVER. VALVE

OPEN

CAPA
RUN
HP
BP

R
S

INDICATOR RELAY

R2 STAGING RELAY
AC LOAD

BLOWER
CYCLE
VALVE

C1

T1
R1

T2
C2
SENSOR

-
SENSOR
DISPL.

WATER

+
DIGIT.

AIR

COMP1

CIRCULATION PUMP
HP
BP
DIPSWITCH SELECTOR

FAN
PUMP2

220V
PUMP1

GND
COMP2
220V

COMP1 PUMP1 VALVE

FAN PUMP2
SEAWATER PUMP
AC SUPPLY 230V

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 21

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 DIPSWITCH SELECTOR
BP REVER.VALVES
AC SUPPLY 230V/ELECTRONICS/PUMPS
1

HP
2

BP
3

OPEN
4

HP

EDITION DATED 21ST AUGUST 2006

BP
BLACK = PUSHED DOWN

BP
ATT. DIPSWITCH SETTINGS

AC SUPPLY COMPR. 2 HP

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HP
230V

230V
COMP1

FAN
COMP1 COMP2
PUMP2
VALVE
COMP2

PUMP1
TO COMPR. 2

FAN
POWER-RELAY
COMPR. 2 - CAN
BE SINGLE PHASE C1
OR 3 PHASE, CYCLE
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 22

ACCORDING TO R1 INDICATOR RELAY POWER-RELAY

COMPRESSOR COMPR. 1 - CAN
T1 BE SINGLE PHASE
CHOICE
OR 3 PHASE,

PUMP1 VALVE
C2 ACCORDING TO
AC LOAD COMPRESSOR
R2 STAGING RELAY
CHOICE
T2

PUMP2
GND
TO COMPR. 1

BLOWER

AC SUPPLY COMPR. 1
SEAWATER PUMP
CIRCULATION PUMP
11.2 - WIRING DIAGRAM WBCP CONDENSING UNITS - 1/3 PHASE - COMPRESSORS 1 AND 2

2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 22

 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 23

11.3 - WIRING DIAGRAM WBCP CONDENSING UNITS - 1/ 3 PHASE - COMPRESSORS 3 AND 4

ATT. DIPSWITCH SETTINGS

BLACK = PUSHED DOWN
1 2 3 4

OPEN

3 PHASE AS REQUIRED

3 PHASE AS REQUIRED
TO COMP4
TO COMP3
SINGLE PHASE OR

SINGLE PHASE OR
POWER-RELAY

POWER-RELAY

AC SUPPLY COMP4
HP - COMP3

HP - COMP4

AC SUPPLY COMP3
BP - COMP3

BP - COMP4

COMP4
COMP4
COMP3
HP
BP

COMP3
HP

230V

TO CONNECTORS 230V - TECC MAIN BOARD

BP

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 23

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 24

11.4 - POWER-SUPPLY SCHEMATICS - CHILLER UNITS TWIN/CI - SINGLE PHASE 230V

TO THE RIGHT OF DASHED LINE : PREWIRED BY FACTORY

POWER RELAY COMPRESSOR 1

TO CONNECTORS COMP1 - TECC CARD

C1
MAIN SUPPLY COMPR. 1
C1
C2
MAIN SUPPLY COMPR. 2 POWER RELAY COMPRESSOR 2
C2
PH
MAIN SUPPLY TECC + ACCESSORIES
N
T

TO CONNECTORS COMP2 - TECC CARD

TO CONNECTORS 230 AC IN - TECC CARD

CLD TERMINAL CONNECTION STRIP INSIDE ELECTRICAL BOX

TO THE LEFT OF DASHED LINE - TO BE WIRED BY CLIENT

11.5 - POWER-SUPPLY SCHEMATICS - CHILLER UNITS TRI/CI - SINGLE PHASE 230V

TO THE RIGHT OF DASHED LINE : PREWIRED BY FACTORY

POWER RELAY COMPR. 1

TO CONNECTORS COMP1 - TECC CARD

POWER RELAY COMPR. 2

C1
POWER SUPPLY COMPRESSOR 1
C1
TO CONNECTORS COMP2 - TECC CARD
C2
POWER SUPPLY COMPRESSOR 2
C2
C3 POWER RELAY COMPR. 3
POWER SUPPLY COMPRESSOR 3
C3
PH
POWER SUPPLY TECC CARD + ACCESS.
N
T

TO CONNECTORS COMP3 - TECC CARD

TO CONNECTORS AC230 IN - TECC CARD

CLD TERMINAL CONNECTION STRIP INSIDE ELECTRICAL BOX

TO THE LEFT OF DASHED LINE : TO BE WIRED BY CLIENT

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 24

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 2000 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 25

11.6 - POWER-SUPPLY SCHEMATICS - CHILLER UNITS TRI/CI - 3 PHASE 400V

TO THE RIGHT OF DASHED LINE : PREWIRED BY FACTORY

POWER RELAY COMPRESSOR 1

TO CONNECTORS COMP1 - TECC CARD

C1
MAIN SUPPLY COMPR. 1 C1
C1 POWER REALY COMPRESSOR 2
C2
MAIN SUPPLY COMPR. 2 C2
C2 TO CONNECTORS COMP2 - TECC CARD
C3
MAIN SUPPLY COMPR. 3 C3
C3 POWER RELAY COMPRESSOR 3
PH
MAIN SUPPLY TECC CARD + ACCESSORIES
N
T

TO CONNECTORS COMP3 - TECC CARD

TO CONNECTORS 230AC IN - TECC CARD

CLD TERMINAL CONNECTION STRIP INSIDE ELECTRICAL BOX

TO THE LEFT OF DASHED LINE :TO BE WIRED BY CLIENT

11.7 - POWER-SUPPLY SCHEMATICS - CHILLER UNITS QUATRO/CI - 3 PHASE 400V

TO THE RIGHT OF DASHED LINE : PREWIRED BY WEBASTO

POWER RELAY
COMPR. 1

TO CONNECTORS COMP1 - TECC CRD

POWER RELAY
COMPR. 2

MAIN SUPPLY
COMPR. 1
TO CONNECTORS COMP2 - TECC CRD
MAIN SUPPLY POWER RELAY
COMPR. 2 COMPR. 3

MAIN SUPPLY
COMPR. 3
TO CONNECTORS COMP3 - TECC CRD
MAIN SUPPLY
COMPR. 4 POWER RELAY
COMPR. 4
MAIN SUPPLY TECC CARD + ACCESS.

TO CONNECTORS COMP4 - TECC CRD

TO CONNECTORS 230AC IN - TECC CARD

WEBASTO TERMINAL STRIP INSIDE WEBASTO ELECTRICAL BOX

TO THE LEFT OF DASHED LINE : TO BE WIRED BY CLIENT

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 25

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 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 26

11.8 - WIRING SCHEMATICS - 11.9 - WIRING SCHEMATICS - RUNNING

AUTOMATIC STAGING RELAY - SECONDARY CAPACITORS FOR BLOWER MOTERS -
230V ON-BOARD FUNCTIONS ECOFIT/EBM

BLOWER MOTER
CABLE FROM
TECC - CHILLER - CONTROLLER CARD

CONNECTION
GND WIRE

WIRE
BROWN

CAPACITOR
BLACK

RUNNING
BLACK
230V POWER-RELAY -
CONTACTS NORMALLY CLOSED
DELESTAGE

BLUE
PHASE
230V ON-BOARD SUPPLY - TO AUTOMATICALLY STAGED FUNCTIONS

NEUTRAL

230V SUPPLY

11.9 - WIRING SCHEMATICS - Connection 3-Way valve (Lizhan/Zhongli) on TECC card

EDITION DATED 21ST AUGUST 2006 2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 26

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