Webasto Cool Top 110 User manual

Operating and Installation Instructions
Air Conditioning
Cool Top 110 | 140 | 190 | 220 | 250 | 300 | 360 RT-C
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AUTO
MENU
Bedienungs- und Einbauanweisung
Notice d’utilisation et de montage
Istruzioni per l'uso e istruzioni di montaggio
Instrucciones de uso y montaje

Cool Top 2
Table of Contents
1 About this document 3
1.1 Purpose of the document 3
1.2 Using this document 3
1.3 Use of symbols and highlighting 3
1.4 Warranty and liability 3
2 Safety 3
2.1 General safety 3
2.2 Intended use 3
3 Operation 4
3.1 Control element 4
3.2 Buttons 4
3.3 Display 4
3.4 Switch system ON 4
3.5 Switch system OFF 4
3.6 Temperature set during operation 4
3.7 Ventilation speed regulation 5
3.7.1 Manual speed regulation 5
3.7.2 Automatic regulation 5
3.8 Recirculated or fresh air mode 5
3.9 Climate control 5
3.9.1 Manual cooling 5
3.9.2 Automatic regulation 5
4 User menu settings 6
5 Error codes 6
6 Configuration menu 7
7 Installation 8
7.1 Display dimensions 8
7.2 Display connector 8
8 Technical data 8
9 Technical support and customer service 8
9.1 CE-Declaration of Conformity 8
10 Disposal 8
11 Maintenance 9

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1 About this document
1.1 Purpose of the document
The operating instructions are part of the product and provides
the user with information on the safe operation of the unit.
1.2 Using this document
XRead these operating instructions before operating the unit.
XKeep these operating instructions ready to hand.
XHand these operating instructions on to the following owner or
user of the unit.
1.3 Use of symbols and highlighting
Explanation

Action to be taken

Requirements for the following necessary action
Note on a special technical feature
Separate information is available
Possibility on property damage
Possibility on a severe or mortal injury
1.4 Warranty and liability
Webasto shall not assume liability for defects or damage that are
the result that the installation and operating instructions as well as
the instructions contained therein being disregarded.
This liability exclusion particularly applies for:
■improper use
■repairs not carried out by a Webasto service workshop
■use of non-genuine parts
■conversion of the unit without permission from Webasto
■mechanical damage to the equipment
■failure to comply with inspection and maintenance instructions
2 Safety
2.1 General safety
Please note that the configuration of the insulation/cooling affects
the storage capacity of the vehicle. When making use of the maxi-
mum storage capacity and the seats, also comply with the permis-
sible axle load.
2.2 Intended use
The control element is designed to control Webasto Cool Top
air conditioning systems for:
■mini-bus
■midi-bus
■bus
ATTENTION
Misuse as a result of failure to comply with the
operating instructions
Result: damage to the A/C system
XFollow the operating instructions.
The performance values of your application are closely
related to ambient conditions, vehicle insulation, etc.
The actual temperature may therefore deviate from the
set value.
The A/C system only operates with the vehicle engine
running.
In the case of vehicles fitted with automatic start-stop
control, the function must be switched off while ope-
rating the A/C system. For information on the control
and function of the automatic start-stop control, please
read the operating instructions for your vehicle.

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3 Operation
3.1 Control element
AUTO
MENU
5
4
3
67
1
2
9
8 10
11
12
13
Fig. 01: Control element
3.2 Buttons
1Up - increase values (temperature)
2
AUTO
A/C system in Automatic mode
■With indicator bar: ON - green
3Down - decrease values (temperature)
4Manual cooling ON / OFF
■With indicator bar: ON - blue
5Heating (not on standard version)
Only when fuel operated heater is installed
6User menu settings
7
MENU
Menu
■“Enter” button
8Configuration menu
9Air recirculation mode ON / OFF
■With indicator bar: ON - green
10 A/C system ON / OFF
■With indicator bar: ON - green, OFF - red
11 Up - increase values (blower speed)
12 Manual blower speed (Ventilation)
■With back-light ON
13 Down - decrease values (blower speed)
3.3 Display
1
2
3
4
5
Fig. 02: Display
Description See par.
1 Temperature units indication (°C/°F) 3.9.2
2 Set-point 3.6
3 Ventilation speed / mode (AUTO, S1 - S6) 3.7
4 Set-point temperature 3.6
5 Error codes (For example E130) 5
3.4 Switch system ON
3Screen in OFF mode
Press "On/Off" button.
– The indicator bar lights green.
– The compressor and the fan will start up.
3.5 Switch system OFF
During a short vehicle stoppage, e.g. during loading / unloading,
you do not need to switch the system off using the control ele-
ment. The system will start up automatically the next time you
start the engine.
3Screen in ON mode
Press "On/Off" button.
– The indicator bar lights red.
3.6 Temperature set during operation
3System is switched ON.
XPress button “Up” to increase the temperature value.
XPress button “Down” to decrease the temperature
value.
AUTO
XPress button “AUTO” to switch ON or OFF.
– Auto mode OFF: Indicator light is off.
– Auto mode ON: Indicator lights green.
The temperature value (Set-point) is stored in the control element.
The temperature range is limited between 18°C and 28°C
The display shows:
■“Lo” when temperature is set lower than 18°C.
– The A/C system runs at maximum cooling capacity.
■“Hi” when temperature is set higher than 28°C.
AUTO
MENU
MENU

Cool Top 5
– The A/C runs at maximum heating capacity (Only if heating kit
is installed).
3.7 Ventilation speed regulation
There are two ventilation modes:
– Manual speed regulation
– Automatic regulation
3.7.1 Manual speed regulation
XPress button “Blower” to switch to manual speed reg-
ulation.
– Ventilation back-light is on.
XPress button “Up” to increase the ventilation speed.
XPress button “Down” to decrease the ventilation
speed.
– Automatic speed regulation is disabled.
– The ventilation speed is fixed.
Cool Top Speed variations
110/140/190/220 RT-C S1, S2 and S3
190 RT-CW S1, S2, S3, S4, S5 and S6
250/300/360 RT-C S1, S2, S3, S4, S5 and S6
3.7.2 Automatic regulation
AUTO
XPress button “AUTO” to switch to automatic speed
regulation.
– Ventilation back-light is off.
– The ventilation speed depends on the difference be-
tween temperature setting and the actual measured
temperature.
– The automatic regulation adjusts also the climate
control
3.8 Recirculated or fresh air mode
The fresh air mode is only available on systems with
fresh air kit installed.
The fresh air mode is optional. Contact Webasto.
Air is drawn in from the outside (fresh air mode) or recirculated in-
side (recirculated air mode).
3Recirculation back-light is on.
XPress button “Recirculation” to switch to recirculation
mode.
– Indicator lights green.
3.9 Climate control
There are two operation modes for climate control:
1. Manual cooling.
2. Automatic regulation.
“Heating” is only aivailable when a heating kit is in-
stalled. If no heating kit is installed the system only uses
the cool mode.
3.9.1 Manual cooling
3Screen is on
3Cooling indicator is off
XPress button “Manual Cooling”.
– Manual cooling indicator lights blue
– “AUTO” indicator is off
3Screen is on
3Cooling indicator lights blue
XPress button “Manual Cooling” to switch off the A/C.
– Manual cooling indicator is off
3.9.2 Automatic regulation
The system controls the ventilation and, depending on the tem-
perature set-point, the system heats or cools the vehicle passenger
compartment.
AUTO
3Screen is on
XPress button “AUTO” to switch ON or OFF.
– Auto mode OFF: Indicator light is off.
– Auto mode ON: Indicator lights green.
The automatic regulation adjusts also the ventilation
speed.
AUTO
MENU
AU
T
O
MEN
U
AUTO
MENU
A
U
T
O
ME
NU
AUTO
MENU
A
U
T
O
ME
NU

Cool Top 6
4 User menu settings
The user can adjust the following settings:
■Temperature unit (°C / °F), display shows “Tum”
■Display back-light, display shows “Dim”
6 +
MENU
XPress and hold buttons 6 and “MENU” for 3 sec.
– The user menu opens.
XPress button “Recirculation” or “Cooling” to
switch between menu items.
MENU
XPress button “MENU” to select menu item.
XPress button “Recirculation” or “Cooling” to ad-
just the parameter.
MENU
XPress button “MENU” to save the parameter val-
ue.
5 Error codes
If an error occurs the display
shows an error code.
Error
code Description Troubleshooting
033 Empty refrigerant cir-
cuit
Check refrigerant charge. Check
refrigerant leakage. Refill.
118 Short circuit on one
of the digital outputs
Check digital output and relays.
120 Water valve feedback Check water valve and its con-
nections
125 Short circuit with
sensor
Check NTC 2 Supply air tempera-
ture sensor
127 Short circuit with
sensor
Check NTC 1 Internal tempera-
ture sensor
129 Short circuit with
sensor
Check NTC3 External tempera-
ture sensor
130 Short circuit with
sensor
Check NTC4 Internal auxiliary
temperature sensor
132 Short circuit with
transducer
Check low pressure transducer
connection
133 Short circuit with
transducer
Check high pressure transducer
connection
143 Broken connection
with sensor
Check NTC2 Supply air tempera-
ture sensor
145 Broken connection
with sensor
Check NTC1 Internal tempera-
ture sensor
147 Broken connection
with sensor
Check NTC3 External tempera-
ture sensor
148 Broken connection
with sensor
Check NTC4 Internal auxiliary
temperature sensor
150 Broken connection
with transducer
Check low pressure transducer
connection
151 Broken connection
with transducer
Check high pressure transducer
connection
162 Battery overvoltage Check battery. Power supply volt-
age above 16V (12V) or 32V
(24V).
163 Battery undervoltage Check battery. Power supply volt-
age below 9V (12V) or 18V
(24V).
164 Transducers supply
(5V) undervoltage
Check transducers supply line.
Power supply voltage below
4,95V.
167 Overcurrent fresh air
motor
Check motor and its connections.
Current over 1.5A.
168 Overcurrent water
valve
Check water valve and its con-
nections. Current over 1.5A.
Tbl. 01: Error codes
AUTO
MENU
AU
T
O
6

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6 Configuration menu
There are several options for the Cool Top. The installer supplies a
working system with the control element configured according
the installed options.
If the system changes or a new control element need to be in-
stalled then the configuration need to be changed.
ATTENTION
If you are unfamiliar with the system then do not
change settings. Only a Webasto service workshop
can use this menu.
Result: Change of settings could lead to system malfunc-
tion.
XContact Webasto in case you have doubts about the
configuration settings.
MENU
+ 8 XPress and hold buttons “MENU” and 8 for 3 sec.
– The configuration menu opens.
XPress button “Recirculation” or “Cooling” to
switch between menu items, see Tbl. 02.
MENU
XPress button “MENU” to select menu item.
XPress button “Recirculation” or “Cooling” to ad-
just the parameter.
MENU
XPress button “MENU” to save the parameter val-
ue.
AUTO
MENU
AU
T
O
8
Parameter Code Parameter Name
Default Value for Cool Top
Range R/W* Description
110/140 190/220 250/300/360
Ext External temperature sensor
(NTC3)
--- --- --- --- R Measures the external air tempera-
ture
In1 Internal temperature sensor
(NTC1)
--- --- --- --- R Measures the internal air tempera-
ture
In2 Internal auxiliary temperature
sensor (NTC4)
--- --- --- --- R Measures the Internal air tempera-
ture
Mix Supply air temperature sen-
sor (NTC2)
--- --- --- --- R Measured the supplied air tempera-
ture
Vb Vehicle battery voltage --- --- --- --- R Measures the battery voltage
Vs Sensor supply voltage (5V) --- --- --- --- R Current value measured of the sen-
sors voltage
Rel Release Software --- --- --- --- R Display 102 is version 1.02
Cnf Configuration of the operat-
ing mode
0 0 0 0-1 R/W 0 = A/C (without heating kit)
1 = HVAC (with heating kit)
Act Activation of fresh air 0 1 1 0-1 R/W 0 = Fresh air kit not present
1 = Fresh air kit present
Ntc Activation of internal auxilia-
ry temperature sensor
(NTC4)
0 0 0 0-1 R/W 0 = only internal air sensor present
1 = both internal and auxiliary air
sensors present
Bat Configuration of vehicle bat-
tery
0 1 1 0-1 R/W 0 = 12V / 1 = 24V
Blw Configuration of the blowers
mode
(ONLY for Cool Top RT-CW)
--- 0 --- 0-1 R/W 0 = 3 speeds (S1, S2 and S3)
1 = linear speed for Cool Top RT-
CW (S1, S2, S3, S4, S5 and S6)
Cmp Configuration of the com-
pressor type
--- 0 --- 0-1 R/W 0 = Short time delay compressor
(Sanden, Valeo)
1 = Long time delay compressor
(Bock)
Out Exit from menu --- --- --- --- -- Exit from configuration menu
* R = Read only / W = Write
Tbl. 02: Control element parameters

Cool Top 8
7 Installation
Find the right place in the drivers cabin where the display will fit.
ATTENTION
Wrong chosen location for cut-out
Result: Damage of wiring and or components behind
the panel.
XCheck space behind panel before making the
cut-out.
7.1 Display dimensions
Fig. 03:
112 mm / 4,41”
68,2 mm /
2,685”
138 mm / 5,43”
55 mm / 2,17”
12 mm / 0,47” 14,6 mm / 0,57”
13 mm / 0,52”
Display dimension
3Location for control panel has been checked
XMake a cut-out of 112 mm wide and 55 mm high.
7.2 Display connector
Fig. 04:
1
3
13
15
6 pin connector
Pin Remark Wire num-
ber Wire colour
1 --
2 --
3 --
4 --
5 --
6 GND B-17 Black
7 +12VDC / +24VDC 027 Red
8 CAN L 012 Green
9 CAN H 013 Yellow
10 --
11 --
12 --
13 --
14 --
15 --
Tbl. 03: 6 pin connector, pin assignment
8 Technical data
Description Value
Operating voltage range [V] 12-24
Current consumption [mA] 50
Output short circuit protection Protected
Polarity reverse protection Protected
Operating temperature range [°C] -40 to +80
Temperature sensor NTC 10 kΩ @ 25°C
Protection IEC-60529 (front panel) IP54
9 Technical support and
customer service
Do you have any technical questions or problem with the device?
National phone numbers of our representatives are provided on
the following website: www.webasto.com.
9.1 CE-Declaration of Conformity
Webasto hereby declares that the control element conforms
UNECE Regulation No. 10
The complete text of the CE-declaration of conformity is available
on the download area of https://dealers.webasto.com
10 Disposal
When you eventually decommission the system, please dispose of
the individual components properly at a recycling centre

Cool Top 9
11 Maintenance
Component
Item Possible
reason
Period
5,000 km 35,000 km Annual or
100,000 km
Compressor
Compressor belt Wear Change
Belt tension (it is important that the belt is al-
lowed to cool before re- tensioning)
Loose tension Check/Repair Check/Repair
Idle pulley Noise/Blocked Change
Automatic belt tightener (if present) Noise/Blocked Change
Tightening bolts Loose fastening Check/Repair
Compressor Noise/Blocked Check/Repair
Compressor pulley Clutch engagement Check/Repair
Evaporator and Condenser
Drier filter Poor efficiency Change
Condenser fin Dirty/Leakage Check/Repair
Evaporator fin Dirty/Leakage Check/Repair
Condensation drain water Water inside vehicle Check/Repair
Centrifugal blower or axial fan Noise/Blocked Check/Repair
Others
Internal temperature Poor A/C efficiency Check/Repair
A/C system pressure test Poor A/C efficiency Check/Repair
Integrity of wiring connections No work or intermit-
tent operation
Check/Repair
Status of refrigerant pipes and fittings A/C systems empty
Poor A/C efficiency
Check/Repair
Refrigerant R134a charge A/C systems empty
Poor A/C efficiency
Refill
Oil compressor Oil removed during
charging of the refri-
gerant
Refill
Tightening control Blocked Check/Repair
Tbl. 04: Maintenance

Cool Top 10
Inhaltsverzeichnis
1 Zu diesem Dokument 2
1.1 Zweck des Dokuments 2
1.2 Umgang mit diesem Dokument 2
1.3 Verwendung von Symbolen und Hervorhebungen 2
1.4 Gewährleistung und Haftung 2
2 Sicherheit 2
2.1 Allgemeine Sicherheit 2
2.2 Bestimmungsgemäße Verwendung 2
3 Bedienung 3
3.1 Bedienelement 3
3.2 Tasten 3
3.3 Display 3
3.4 System einschalten 3
3.5 System ausschalten 3
3.6 Temperatur einstellen während des Betriebs 3
3.7 Drehzahlregelung der Lüftung 4
3.7.1 Manuelle Drehzahlregelung 4
3.7.2 Automatische Drehzahlregelung 4
3.8 Umluft- und Frischluftbetrieb 4
3.9 Temperaturregelung 4
3.9.1 Manuelle Kühlung 4
3.9.2 Automatische Regelung 4
4 Benutzermenü-Einstellungen 5
5 Fehlercodes 5
6 Konfigurationsmenü 6
7 Einbau 7
7.1 Abmessungen Display 7
7.2 Displaystecker 7
8 Technische Daten 7
9 Technische Unterstützung und Kundendienst 7
9.1 CE-Konformitätserklärung 7
10 Entsorgung 7
11 Wartung 8